Method for the Manufacture of a Plastic Component, Plastic Component, Midsole and Shoe

ABSTRACT

The present invention relates to an enhanced method for the manufacture of a plastic component (135), in particular a cushioning element for sports apparel, the method comprising: opening a mold (100) by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts (110, 112) and wherein the amount by which the mold is opened influences an available loading volume of the mold, loading a material comprising expanded particles (130) into the loading volume, closing the mold into a closed position, wherein during closing of the mold the mold parts are moved together over different distances (140) in different areas of the mold, compressing the expanded particles by closing the mold and fusing at least the surfaces of the expanded particles to mold the plastic component.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/465,485, filed May 30, 2019, entitled “Method for the Manufacture ofa Plastic Component, Midsole, and Shoe” (the '485 application), which isa U.S. national phase patent application of PCT/EP2017/080420, filedNov. 24, 2017, entitled “Method for the Manufacture of a PlasticComponent, Midsole and Shoe” (the '420 application), which is based onGerman Patent Application No. 102016223980.5, filed on Dec. 1, 2016,entitled “Method for the Manufacture of a Plastic Component, Midsole andShoe” (the '980 application). The '485, '420, and '980 applications arehereby incorporated herein in their entireties by this reference.

FIELD OF THE INVENTION

The present invention relates to a method for the manufacture of aplastic component, in particular a cushioning element for sportsapparel, a plastic component manufactured with such a method, as well asa midsole and a shoe.

BACKGROUND

Nowadays, plastic components play an essential role in many areas oftechnology and everyday life. As examples, the aviation and aerospaceindustry as well as the automotive industry are mentioned. In theseareas, plastic components may, for example, serve as impact protectionelements, e.g. bumpers, or they may be used for the manufacture ofpanel-elements, seat shells, arm rests, and so forth. Plastic componentsmay also be used in the packing industry, for example for packing upsensitive and easily damaged goods for delivery.

In all of these exemplary areas of application, it is beneficial if theplastic components comprise as small a weight as possible, being,however, at the same time sufficiently resilient. In particular, withregard to plastic components being used for impact protection or forsafely wrapping up goods, plastic components should also comprise goodcushioning and shock absorption properties with regard to blows or hits.In this context, foamed plastic materials are known from the prior art,like for example expanded polystyrene—e.g. available from the BASF underthe trade names of Styropor® or Styrodur®.

The use of expanded plastic materials has also found its way into themanufacture of cushioning elements for sports apparel, for example forthe manufacture of shoe soles for sports shoes.

In the art of shoe manufacturing and in particular, in the design ofhigh performance athletic shoes a strong demand exists for improving thematerial properties of the individual components of a shoe, for examplethe flexibility, the abrasion resistance, the stiffness, the compressivestrength and/or the resilience of the component as well as furtherphysical and chemical material properties.

For instance, it may be desirable to enhance the material properties ofthe midsole of an athletic shoe, in order to provide a higherperformance of the shoe during use, improved wearing comfort and/orincreased longevity of the midsole while at the same time improving easeof manufacture.

In particular, the use of particles of expanded thermoplasticpolyurethane (eTPU), which are fused together by supplying heat in theform of steam or connected by the use of a binder material as describedin DE 10 2012 206 094 A1 and DE 10 2011 108 744 B1, has been considered.

Moreover, prior art document EP 2 649 896 B1 provides improved soles andinsoles for shoes, in particular sports shoes and manufacturing methodsthereof. In one aspect, a sole for a shoe, in particular a sports shoe,with at least a first and a second surface region is provided, whereinthe first surface region comprises eTPU.

In addition, the EP 3 114 954 A1 relates to a method for the manufactureof a sole for a shoe, in particular for a sports shoe that comprises:opening a movable part of a mold to a predetermined extent, loadingparticles of eTPU into the mold, reducing the volume of the moldaccording to the shape of the sole which is to be manufactured andfeeding steam to the eTPU, wherein the mechanical properties of the soleare at least partly determined by the extent to which the mold is openedduring loading.

However, various aspects of the manufacturing methods described by theprior art may be further improved.

It is therefore a problem to be addressed by the present invention tofurther improve manufacturing methods for a plastic component comprisingexpanded particles such as eTPU or expanded polyether-block-amide(ePEBA) so as to improve the material properties and/or ease ofmanufacture of the plastic component.

Further, it is desirable to incorporate such enhanced plastic componentcomprising expanded particles into a midsole of a shoe and/or a shoe.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this patent are intended to refer broadly toall of the subject matter of this patent and the patent claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or to limit the meaning or scope of thepatent claims below. Embodiments of the invention covered by this patentare defined by the claims below, not this summary. This summary is ahigh-level overview of various embodiments of the invention andintroduces some of the concepts that are further described in theDetailed Description section below. This summary is not intended toidentify key or essential features of the claimed subject matter, nor isit intended to be used in isolation to determine the scope of theclaimed subject matter. The subject matter should be understood byreference to appropriate portions of the entire specification of thispatent, any or all drawings and each claim.

In some embodiments, the disclosure relates to a method for themanufacture of a plastic component, the method comprising: a. opening amold by a predetermined amount into a loading position; wherein the moldcomprises at least two mold parts and wherein the amount by which themold is opened influences an available loading volume of the mold; b.loading a material comprising expanded particles into the loadingvolume; c. closing the mold into a closed position; wherein duringclosing of the mold the at least two mold parts are moved together overdifferent distances in different areas of the mold; d. compressing theexpanded particles by closing the mold; e. fusing at least the surfacesof the expanded particles to mold the plastic component. The differentdistances may locally affect the degree of compression of the expandedparticles. The different distances may be related to the thicknessdistribution in the molded plastic component at least for a section ofthe mold. The expanded particles may be partially fused together byheated steam and/or electromagnetic radiation. During closing of themold, at least one of the mold parts may be pivoted around aneccentrically arranged swivel axis. The swivel axis may be connected toa mounting plate. Deformable spacer elements of different length may bearranged between the mounting plate and the at least one mold part. Atleast one of the mold parts may comprise several individual sub-parts,and wherein the different distances over which the mold parts are movedtogether may be individually controlled for each sub-part. The mold maybe sealed after the step of loading the mold volume with expandedparticles so that the remaining steps of the method are executed at adifferent location than the step of loading the mold. The plasticcomponent may be a cushioning element for a sports shoe.

In some embodiments, the disclosure relates to a plastic component,comprising expanded particles, wherein the local density and/or thelocal compression stiffness of the plastic component is determined bythe degree of local compression of the expanded particles during moldingof the component. The local density and/or the local compressionstiffness of the plastic component may be essentially constant in atleast a portion of the plastic component. The local density and/or thelocal compression stiffness of the plastic component may be essentiallyconstant in all of the plastic component. The expanded particles maycomprise at least one of the following materials: expanded thermoplasticpolyurethane (eTPU); expanded polyamide (ePA); expandedpolyether-block-amide (ePEBA); expanded polylactide (ePLA); expandedpolyethylene terephthalate (ePET); expanded polybutylene terephthalate(ePBT); expanded thermoplastic polyester ether elastomer (eTPEE). Theplastic component may be produced by the method comprising: a. opening amold by a predetermined amount into a loading position; wherein the moldcomprises at least two mold parts and wherein the amount by which themold is opened influences an available loading volume of the mold; b.loading a material comprising expanded particles into the loadingvolume; c. closing the mold into a closed position; wherein duringclosing of the mold the at least two mold parts are moved together overdifferent distances in different areas of the mold; d. compressing theexpanded particles by closing the mold; e. fusing at least the surfacesof the expanded particles to mold the plastic component. The differentdistances may locally affect the degree of compression of the expandedparticles. The different distances may be related to the thicknessdistribution in the molded plastic component at least for a section ofthe mold. The expanded particles may be partially fused together byheated steam and/or electromagnetic radiation. During closing of themold, at least one of the mold parts may be pivoted around aneccentrically arranged swivel axis. The swivel axis may be connected toa mounting plate. Deformable spacer elements of different length may bearranged between the mounting plate and the at least one mold part. Atleast one of the mold parts may comprise several individual sub-parts,and wherein the different distances over which the mold parts are movedtogether may be individually controlled for each sub-part. The mold maybe sealed after the step of loading the mold volume with expandedparticles so that the remaining steps of the method are executed at adifferent location than the step of loading the mold. The plasticcomponent may be a cushioning element for a sports shoe. In someaspects, the plastic component may be a midsole and the compressionstiffness of the midsole may vary by less than 20% over essentially thewhole extent of the midsole. In some aspects, a shoe comprises themidsole described herein.

In some embodiments, the disclosure relates to a midsole for a shoecomprising expanded particles, wherein the local density of the midsolevaries by less than 20% over essentially the whole extent of themidsole. The expanded particles may comprise at least one of thefollowing materials: expanded thermoplastic polyurethane (eTPU);expanded polyamide (ePA); expanded polyether-block-amide (ePEBA);expanded polylactide (ePLA); expanded polyethylene terephthalate (ePET);expanded polybutylene terephthalate (ePBT); expanded thermoplasticpolyester ether elastomer (eTPEE).

BRIEF DESCRIPTION OF THE DRAWINGS

In the following detailed description, embodiments of the invention aredescribed referring to the following figures:

Embodiments of the present invention are described in more detail in thefollowing by reference to the accompanying figures. These figures show:

FIG. 1 a : a schematic longitudinal cross-section of a mold in theloading position according to embodiments of the present invention;

FIG. 1 b : a schematic longitudinal cross-section of a mold in theclosed position according to embodiments of the present invention;

FIG. 1 c : a schematic longitudinal cross-section of a mold in theclosed position and during fusing of the expanded particles according toembodiments of the present invention;

FIG. 1 d : a schematic longitudinal cross-section of a mold in theduring releasing the plastic component from the according to embodimentsof the present invention;

FIG. 2 a schematic of a mold design adapted to be used in a methodaccording to the present invention;

FIG. 3 a : a bottom view of a midsole of an athletic shoe according toembodiments of the present invention;

FIG. 3 b : a side view of a midsole of an athletic shoe according toembodiments of the present invention;

FIG. 3 c : a bottom view of a midsole of an athletic shoe according toembodiments of the present invention; and

FIG. 4 : a comparison the variation of density of midsoles producedaccording to the present invention and of midsoles produced byconventional molding techniques for expanded particles.

BRIEF DESCRIPTION

The above-mentioned objectives are at least partly fulfilled by thesubject matter of the claims of the present application.

In some embodiments, the present invention provides a method for themanufacture of a plastic component, in particular a cushioning elementfor sports apparel comprising a step of opening a mold by apredetermined amount into a loading position, wherein the mold comprisesat least two mold parts and the amount by which the mold is openedinfluences an available loading volume of the mold, a step of loading amaterial comprising expanded particles into the loading volume, a stepof closing the mold into a closed position, wherein during closing ofthe mold the mold parts are moved together over different distances indifferent areas of the mold, a step of compressing the expandedparticles by closing the mold and a step of fusing at least the surfacesof the expanded particles to mold the plastic component.

Expanded particles are sometimes also called “foam particles”, and themolded plastic components are consequently sometimes called “particlefoam components”. Other terms by which such expanded particles may bereferred to include “beads” or “pellets”, for example.

For example, the method allows to improve the control over the localcompression of the expanded particles during manufacture of a plasticcomponent such that the plastic component may exhibit superior materialproperties. The material properties such as the density and/or thecompression stiffness of a plastic component may be tailored to aspecific application or use. For example, the local density/compressionstiffness of a plastic component used in athletic shoes may be optimizedand adapted for different types of athletic activity, for exampletennis, running, football, basketball etc. and/or optimized fordifferent surfaces, for example forest trail, asphalt, concrete, sand,grass, hardwood, etc. and/or to the anatomical features and/or gait ofindividual wearers.

Moreover, such enhanced plastic component may readily be integrated intoother types of sports apparel such as garments with integratedcushioning elements and/or sandals, ski boots, snowboard boots, golfshoes as well as all kinds of protective sports equipment such asgloves, in particular baseball gloves, goalkeeper gloves, and/or boxinggloves, shin guards, knee and/or elbow protectors, helmets, backprotectors and many more.

Further, such enhanced plastic component may also be integrated in abroad variety of sport equipment such as skis, snowboards, skate boards,surf boards, punching targets, fitness gear and many more.

In further embodiments of the invention, the different distances overwhich the mold parts are moved together locally affect the degree ofcompression of the expanded particles.

In further embodiments, the different distances over which the moldparts are moved together are related, preferably essentiallyproportional, to the thickness distribution in the molded plasticcomponent at least for a section of the mold.

For instance, it may be possible to ensure an essentially constantdegree of compression and accordingly an essentially constant density inthe molded plastic component. In this respect and for the remaining partof the application the term “essentially” shall be defined as “withintypical manufacturing tolerances”.

For example, a constant density may be desired for plastic componentswith non-uniform thickness such as wedge-shaped components as forexample shoe soles that also require certain physical materialproperties that are density dependent to be essentially homogenous.

In further embodiments of the invention, the expanded particles are atleast partially fused together by heated steam and/or electromagneticradiation.

For example, these embodiments allow to mold the plastic componentwithout relying on adhesives or gluing agents and also to distribute theheat that is required for fusing the surfaces of the expanded particleshomogenously throughout the volume of the mold.

If electromagnetic radiation is employed the expanded particles are notexposed to the moisture present in heated steam, which may be desiredfor certain embodiments. Additionally, heating the expanded particleswith electromagnetic radiation is more energy efficient and allows tocontrol the dynamics of the fusing process more precisely.

It will be apparent to the person skilled in the art that the presentinvention is also compatible with other conventional molding techniquessuch as compression molding, and many more.

In further embodiments of the invention, during closing of the mold atleast one of the mold parts is pivoted around an eccentrically arrangedswivel axis, wherein the swivel axis is preferably connected to amounting plate and wherein preferably deformable spacer elements ofdifferent length are arranged between the mounting plate and the atleast one mold part.

In this respect, the term “eccentrically” is defined with respect to thetransversal center line of the mold.

For example, these embodiments provide a simple way of implementing thedesired different distances over which the at least two mold parts aremoved together in different areas of the mold during closing of themold.

In further embodiments of the invention, at least one of the mold partscomprises several individual sub-parts, wherein the different distancesover which the mold parts are moved together may be individuallycontrolled for each sub-part.

These embodiments allow to apply different compression schemes to theexpanded particles in different portions of the mold. For example, inone portion of the mold a uniform compression may be desired and in asecond portion a non-uniform compression may be desired. This could berelevant for producing a midsole of a shoe that comprises an essentiallywedge-shaped portion in the midfoot and rearfoot section as well as anessentially uniform portion in the forefoot section.

In further embodiments of the invention, the mold is sealed after thestep of loading the mold volume with expanded particles, such that theremaining steps of the method may be executed at a different location inspace than the step of loading the mold.

For example, these embodiments allow to load the mold at a dedicatedloading station of a multi-station manufacturing line for plasticcomponents. Said loading station may be individually optimized forloading a mold with expanded particles. After loading, the sealed moldmay be transported to further processing stations of the manufacturingline, for example an electromagnetic fusing station that may beindividually optimized for efficient electromagnetic melding of theexpanded particles. By locally separating the subsequent manufacturingsteps and transporting mold from one process station to the next themanufacturing line implementing the method provided by the invention maybe optimized further.

In further embodiments, the present invention provides a plasticcomponent, in particular a cushioning element for sports apparelcomprising expanded particles, wherein the local density and/or thelocal compression stiffness of the plastic component is determined bythe degree of local compression of the expanded particles during moldingthe plastic component.

For example, density dependent mechanical properties of such plasticcomponents comprising expanded particles may be designed according tospecifications relevant for specific applications such as for midsolesfor different kinds of athletic shoes such as basketball, tennis and oroutdoor running shoes.

More specific embodiments of the present invention are related to anenhanced plastic component, wherein the local density and/or the localcompression stiffness of the plastic component is essentially constantin at least a portion, preferably all of the plastic component.

Additional embodiments relate to an enhanced plastic component, whereinthe local density and/or the local compression stiffness of the plasticcomponent is related to, preferably essentially proportional to athickness distribution in at least a portion of the plastic component.

For example, in this way plastic components may be manufactured thatexhibit homogeneous mechanical properties, for example, compressionstiffness and density. Furthermore, plastic components may bemanufactured in a desirable way to produce improved midsoles of sportsshoes.

In further embodiments, the present invention provides a plasticcomponent comprising at least one or more of the following materials:expanded thermoplastic polyurethane (eTPU); expanded polyamide (ePA);expanded polyether-block-amide (ePEBA); expanded polylactide (ePLA);expanded polyethylene terephthalate (ePET); expanded polybutyleneterephthalate (ePBT); expanded thermoplastic polyester ether elastomer(eTPEE).

Further details, regarding expanded particles such as expanded polymerpellets are given by the Applicant's DE 102014216992 A1, the WO2016030026 A1 and the WO2016030333 A1.

For example, the superior material properties of eTPU (or similarexpanded particles) allow to design enhanced cushioning elements forsports apparel. For instance, midsoles for sports shoes comprising eTPUprovide enhanced wearing comfort and superior running properties. Inparticular, such midsole relaxes immediately to its original form afterimpact due its large rebound determined by the resilience of the eTPUmaterial. As a result, impact energy stored in the elastic deformationof the midsole is re-projected to the leg of the wearer and therebyenhances running performance.

In further embodiments, the present invention provides a midsole for ashoe, in particular a sports shoe, comprising a plastic componentaccording to the present invention and produced according to any of themethods provided by the present invention.

In further embodiments, the present invention provides a midsole for ashoe, in particular a sports shoe comprising expanded particles, whereinthe local density of the midsole, varies by less than 20%, preferably byless than 15%, more preferably by less than 10% and most preferably byless than 5% over essentially the whole extent of the midsole.

The local density in the different sections of the midsole may be forexample determined by any related method known in the art that alsoallows to reproducibly determine the density of plastic componentscomprising expanded particles such as expanded TPU.

Additionally or alternatively, the midsole may exhibit a compressionstiffness that varies by less than 20%, preferably by less than 15%,more preferably by less than 10% and most preferably by less than 5%over essentially the whole extent of the midsole.

Additionally or alternatively, the midsole may comprise a plasticcomponent manufactured according to any of the methods provided by thepresent invention.

The compression stiffness of the different sections of the midsole maybe determined by any related method known in the art that also allows toreproducibly determine the compression stiffness of plastic componentscomprising expanded particles such as expanded TPU. One such example isa test method according to ISO 844:2014 “Rigid cellularplastics—Determination of compression properties”.

In further embodiments, the present invention provides a shoe, inparticular a sports shoe comprising a midsole according to theembodiments of the invention mentioned-above.

Such sports shoes for example may provide superior rebound, wearingcomfort and shock cushioning and as a result ensure reduced fatigueexperienced by a wearer and increased running and/or jumping performanceduring use.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

In the following, exemplary embodiments of the present invention aredescribed in more detail with reference to the manufacturing of awedge-shaped plastic component, and in particular a midsole of a sportsshoe. However, it is to be understood that the present invention is notlimited to such specific embodiments but could be applied to other typesof plastic components, that are intended in particular to be used ascushioning elements for sports apparel and sports equipment in general.Moreover, while specific feature combinations are described in thefollowing with respect to certain embodiments of the present invention,it is to be understood that the disclosure is not limited to suchembodiments. In other words, not all features have to be present forrealizing the invention and the embodiments may be modified by combiningcertain features of one embodiments with at least one of the features ofanother embodiment.

FIG. 1 a depicts a longitudinal cross-section of a schematic mold designarranged in the loading position, while expanded particles 130 such aseTPU particles are loaded into the mold 100 a according to someembodiments of the present invention. The loading position may also bedesignated as crack gap position and the mold accordingly as a crack gapmold.

In some embodiments, the expanded particles may all exhibit essentiallythe same size and geometrical shape, wherein in other embodiments thesize and geometrical shape of the expanded particles may differ, infurther embodiments the size and the geometrical shape of the expandedparticles may significantly differ. In further embodiments the expandedparticles may comprise particles of different materials and inparticular mixtures of different polymers, in order to fine-tune thematerial properties of the plastic component.

The expanded particles may further comprise adhesives and/or gluingagents that facilitate the formation of the plastic component inside themold. Moreover, the expanded particles may comprise an energy absorbingmaterial that may for example facilitate energy transfer from anexternally applied electromagnetic field to the expanded particlesinside the mold.

In the presented embodiments the mold 100 a is arranged below areservoir of expanded particles 130 (not shown) such that the expandedparticles 130 are loaded into the mold volume at least in part guided bygravity.

For example, the mold 100 a could be loaded at a loading station from areservoir of expanded particles 130, wherein the reservoir may bearranged above the position of the mold at the loading station. Sincethe reservoir is arranged above the position of the mold 100 a a streamof expanded particles 130 may be guided into the mold 100 a by relyingmainly on gravity without the need for using pressurized air or similarmeans for transporting expanded particles 130. In a similar way themolded plastic component may be demolded from the mold without the needfor dedicated removal means. Both effects reduce the technicalcomplexity of manufacturing and increase efficiency.

Alternatively or additionally, the expanded particles 130 may betransported to the mold 100 a and loaded into the mold volume by atransport and loading mechanism operated for example by pressurized gasand/or pressurized air. Using a loading mechanism based on pressurizedgas and/or air may decrease the time needed for loading of the moldvolume and thus increase production throughput.

The mold 100 a may comprise at least two mold parts 110, 112 which inthe loading position of the mold 100 a may be further apart relative toeach other than in a closed position (see FIG. 1 b ). As a consequence,the mold volume in the loading position is larger than the mold volumein the closed position.

Typically, the mold volume is essentially completely loaded withexpanded particles in the loading position, wherein the expandedparticles are kept essentially in a non-compressed state. The fact thatthe mold volume in the loading position is larger than the volume of themolded plastic component 135 that is formed in the closing position ofthe mold 100 a facilitates to avoid forming undesired voids inside theplastic component 135 and in particular reduces the number of undesiredvoids on the surfaces and along the edges of the plastic component 135.

Moreover, loading the mold 100 a in a loading position with larger moldvolume results in less compression near the opening 150 through whichthe expanded particles are loaded.

It is also possible to vary the loading volume and therefore allow for ahigher or lower total amount of expanded particles inside the mold priorto closing the mold 100 a.

FIG. 1 b depicts the mold 100 b of FIG. 1 a configured in the closedposition after the mold volume has been loaded with expanded particles130 and after the expanded particles 130 have been compressed inside themold 100 b by moving the mold halves 110, 112 from the loading positioninto the closed position.

Due to the compression experienced by the expanded particles 130 duringclosing the mold 100 b the mold volume is essentially homogeneouslyloaded with expended particles that in the closed position are in acompressed state.

In the embodiments illustrated in FIG. 1 b the local distance that themold halves are moved towards each other depends on the thickness of theplastic component such that the degree of compression of the expandedparticles in the closed position is essentially constant across theextent of the plastic component.

This may be achieved by controlling the local distance Δz over which themold parts 110, 112 are moved together such that Δz is essentiallyproportional to the thickness z of the plastic component (i.e. Δz=αzwith proportionality constant α). If the degree of compression λ isdefined as the ratio between the local distance Δz and the localthickness z of the plastic component (i.e. =Δz/z) it is evident that thedegree of compression λ is constant and equal to the proportionalityconstant α.

Such control over the degree of compression may be implemented by acrack gap mold, that is arranged such that the at least two mold partsare arranged pivotable with respect to each other. In particular, one ofthe mold parts or both may be mounted at an eccentric pivot axis suchthat the essentially constant degree of compression is achieved by theone of the mold parts performing a swivelling movement around saideccentric pivot axis and thereby compressing the expanded particlesuniformly.

For other applications of the present invention it may be desirable toproduce plastic components that exhibit a degree of compression λ thatis proportional to the local thickness z of the plastic component 135(i.e. λ=βz). This may be achieved by controlling the local distance Δzover which the mold parts 110, 112 are moved together such that Δz isessentially a quadratic function of the local thickness z of the plasticcomponent 135 (i.e. Δz=βz2).

For further embodiments it may be desirable to produce components thatexhibit a degree of compression λ that is inversely proportional to thelocal thickness z of the plastic component 135 (i.e. =y/z). This may beachieved by controlling the local distance Δz over which the mold parts110, 112 are moved together such that Δz is constant (i.e. Δz=7).

In general, the local thickness z of the plastic component 135 dependson the exact position in the x-y plane of the plastic component i.e. thelocal thickness z is a piecewise continuous function z=z(x, y) of theposition in the x-y plane.

The local distance Δz in turn over which the mold parts 110, 112 aremoved together during closing of the mold may in general also be acontinuous function of the local thickness i.e. Δz=Δz(z). In this mannerthe local degree of compression λ=Δz/z becomes also a piecewisecontinuous function of the position in the x-y plane.

If for example, Δz is a polynomial of degree n in the thickness z thanthe degree of compression is a polynomial of degree n−1 in the localthickness z. The above arguments may be readily generalized to othertypes of functions such as trigonometric functions or exponentials.

Certain mold configurations may allow to directly control the degree ofcompression λ as a quasi-continuous function of position in the x-yplane. This may be achieved by adapting at least one of the mold parts110, 112 such that it comprises a plurality of individually controllablemold elements that are small compared to the extent of the plasticcomponent 135. This technique could for example allow to individuallyadapt the degree of compression of a midsole of a sports shoe to theanatomical shape of the foot of an individual wearer.

The mold 100 b may further comprise means 160 for closing the opening150 through which the expanded particles 130 are loaded into the moldvolume in the loading position. In some embodiments, the means 160 forclosing the opening 150 may be integrated in the mold 100 b. In otherembodiments the means 160 for closing the opening 150 may also beseparate from the mold 100 b and may be detached for loading andattached after loading is completed. In even further embodiments, theopening 150 may be closed from the inside of the mold volume by an outersurface portion of one of the mold parts 110, 112.

FIG. 1 c depicts the mold of FIG. 1 a and FIG. 1 b during fusing of theexpanded particles.

In some embodiments, the expanded particles 130 may be fused together byheating the expanded particles above a respective temperature such thatthe surface portions of the expanded particles melt together and form anessentially completely connected plastic component 135.

In some embodiments the heat may be supplied by heated steam that is fedinto the mold volume.

In some embodiments heat may additionally be supplied by heating at someportions of the mold as for example the two mold parts 110, 112.

In further embodiments heat may be supplied by electromagnetic radiationsuch as RF, MW, Laser, UV or X-ray radiation. The mold parts 110, 112may serve as capacitor plates that may be connected to a high-power RFor MW amplifier.

In order to enhance the energy transfer from the electromagneticradiation to the expanded particles 130, the expanded particles 130 maycomprises at least one energy absorbing material that exhibits a largeabsorption cross-section in the corresponding part of theelectromagnetic spectrum occupied by the electromagnetic radiation thatis supplying the energy for heating and fusing the expanded particles130.

In some embodiments, the mold 100 c may be sealed in the closedposition. After the mold 100 c is sealed it may be transported from aloading station that was used to load the mold volume with the expandedparticles 130 to a dedicated fusing station where fusing the expandedparticles 130 takes place for example by RF or MW heating and/or steamheating.

Such a method may allow to design flexible and highly automatedmanufacturing lines that employ modular process stations for exampleloading, compression, fusing, cooling, demolding stations. The modulardesign of the production process allows to optimize the design and theoperation of each of the stations of the production processindependently.

FIG. 1 d depicts the mold 100 d of FIGS. 1 a-1 c in a configuration whenmolding the plastic component 135 has been finished and the plasticcomponent 135 is being demolded from the mold 100 d. In some embodimentsthe mold 100 d is oriented such that the plastic component can fall outof the mold 100 d by being subjected to gravity, such that no dedicatedremoval means need to be present. In other embodiments dedicated removalmeans may be employed however.

In some embodiments, wherein the mold may have been sealed after loadingthe mold with expanded particles, demolding the plastic component maytake place at a different location then loading the mold and/or fusingthe expanded particles.

For some embodiments, the mold 100 d may be configured such that the twomold parts 110, 112 are attached to the mold assembly such that they maybe easily opened after the plastic component 135 is molded andsufficiently cooled to be ready for demolding.

The production process schematically depicted in FIG. 1 a-1 d may beconfigured such that after demolding the molded part 135 form the mold100 d (as shown in FIG. 1 d ), the mold 100 d may be cleaned for exampleby pressurized air and may be transported back to the loading station(see FIG. 1 a ) such that the production process may be reinitiated.

In other embodiments, for which all process steps are executed at thesame location (i.e. at a combined loading, compression, fusing,demolding station), the mold 100 d just requires to be put back into theloading configuration illustrated in FIG. 1 a in order to start theproduction process anew.

FIG. 2 depicts a particular mold design that allows to implement atleast some of the methods of manufacture provided by the presentinvention. In detail, the mold 200 comprises two mold parts 210 and 212,wherein the first mold parts 212 may be pivoted around an eccentricallyarranged swivel axis 280. The swivel axis in turn is connected to amounting plate 270, such that when the mounting plate 280 is pressedtowards the other mold part 210 the first mold part 212 is pivotedaround the swivel axis 280 by the pressure resulting from compressingthe expanded particles 230 loaded into the mold volume.

The eccentrically swivel axis is arranged eccentrically with respect tothe transversal center line of the mold, resulting in different positiondependent distances over which the two mold parts 210 and 212 are movedtogether, when the first mold part 212 is pivoted around theeccentrically arranged swivel axis 280.

In order to produce wedge-shape plastic components, deformable spacers290, for example spring elements, may be arranged between the mountingplate 270 and the first mold part 212.

The deformable spacers 290 ensure that the two mold parts 210 and 212form a wedge-shape loading volume during loading of the mold 200 withexpanded particles 230 while arranged in the loading position.

The combination of the eccentrically arranged swivel axis 280 with thedeformable spacers 290, that may exhibit different dimensions atdifferent positions along the mounting plate 270, allows to adjust theangle between the two mold parts 210 and 212 in the loading position.

As a consequence, the two mold parts are moved together over differentdistances in different areas of the mold 200 during closing of the moldresulting in a position dependent degree of compression along thelongitudinal extension of the mold 200.

FIG. 3 a depicts a bottom view of an exemplary midsole 300 producedaccording to the presented invention the midsole may comprise a forefootsection 310, a midfoot section 320 and a rearfoot section 330.

In some embodiments all section exhibit a different thickness eithervarying continuously across the midsole 300 or discontinuously.Combinations thereof are also possible, for example the midsole 300 maybe configured such that the thickness varies continuously from theforefoot 310 to midfoot section 320 and discontinuously from the midfootsection 320 to the rearfoot section 330.

Midsoles 300 according to the present invention may also exhibit aconstant or varying density in the respective sections. As for thethickness distribution, the density may also either vary continuouslyand or discontinuously from one section to the adjacent one.

FIG. 3 b depicts a lateral view of the midsole 300 of FIG. 3 a . Theillustrated embodiment shows a continuously varying thicknessdistribution and a non-constant degree of compression. In particular,the expanded particles in the forefoot section 310 are in a morecompressed state than in the midfoot 320 and the rearfoot section 330.This could for example result in a larger rebound in the rear foot 330and the midfoot section 320 than in the forefoot section 310 as it maybe desired for certain types of athletic shoes.

For other types of athletic shoes however it could also be desired, thatthe expanded particles in the forefoot section 310 may be compressed tothe same degree as the expanded particles in the midfoot 320 and/or therearfoot section 330. This may be for example achieved by one of theembodiments of the present invention that provides for compressiondistances at are essentially proportional to the thickness distributionof the midsole 300.

FIG. 3 c depicts the bottom view of FIG. 3 a of a midsole 300 exhibitingan essentially constant degree of compression and/or essentiallyconstant density over essentially the whole extent of the midsole 300.The embodiments shown in FIG. 3 c have been modified by cutting threeessentially cylindrically samples pieces FF, MF, RF out of the midsole300, wherein each sample piece has been cut out from the forefootsection 310, the midfoot section 320 and the rearfoot section 330 of themidsole 300, respectively.

In order to determine the variation of the local density across theextent of the midsole 300 the density of each sample piece FF, MF, RFmay be determined by a density measurement method suitable to measurethe density of plastic components comprising expanded particles.

In case a more detailed density profile of the midsole 300 is required,the size of the sample pieces may be reduced and/or the number of samplepieces that may be cut out of the midsole may be increased.

FIG. 4 shows the results of a density measurement performed on midsolesproduced according to the present invention similar to the one depictedin FIG. 3 c and by using sample pieces of similar shape as illustratedin FIG. 3 c.

FIG. 4 shows the density of the sample pieces each taken from theforefoot section FF, the midfoot section MF and the rearfoot section RFof a midsole 300 produced according to a method provided by the presentinvention. In particular, for producing the test sample midsoles usedfor the density measurement shown in FIG. 4 , a mold design similar tothe one depicted in FIG. 2 has been employed.

Consequently, the expanded particles have essentially been compresseduniformly during molding of the test sample midsoles.

As a result, the local density of the midsole varies by less than 4%between the rearfoot section and the midfoot section and between therearfoot section and the forefoot section. In particular, essentially novariation of density between the midfoot and the forefoot section couldbe determined within the statistical uncertainty of the measurement.

The shown results have been obtained by averaging the measurements over5 test samples of midsoles 300 produced with the same method ofmanufacture, the same mold and the same nominal process parameters.

For example, the average density of the midsole may be between 250 kg/m3and 400 kg/m3, preferably between 275 kg/m3 and 375 kg/m3, morepreferably between 300 kg/m3 and 350 kg/m3 and most preferably between315 kg/m3 and 335 kg/m3.

However, it will be apparent to those skilled in the art that theabsolute values mentioned above and shown in FIG. 4 are exemplary only.The absolute density of the midsole 300 may depend on various parameterssuch as the density of the expanded particles, the type of polymer usedin producing the expanded particles, the degree of expansion theexpanded particles underwent during manufacturing, the degree ofcompression the expanded particles underwent during molding of themidsole 300 and the required compression stiffness of the midsole 300.

In contrast to the present invention molding techniques known from theprior art (e.g. as described in the underlying priority application)result in larger variations of the local density across essentially thewhole extent of the midsole 300.

In the following, further examples are described to facilitate theunderstanding of the invention:

Example 1: Method for the manufacture of a plastic component (135), inparticular a cushioning element for sports apparel, the methodcomprising: a. opening a mold (100) by a predetermined amount into aloading position; wherein the mold (100) comprises at least two moldparts (110, 112) and wherein the amount by which the mold (100) isopened influences an available loading volume of the mold (100); b.loading a material comprising expanded particles (130) into the loadingvolume; c. closing the mold (100) into a closed position; wherein duringclosing of the mold (100) the mold parts (110, 112) are moved togetherover different distances (140) in different areas of the mold (100); d.compressing the expanded particles (130) by closing the mold (100); e.fusing at least the surfaces of the expanded particles (130) to mold theplastic component (135).

Example 2: Method according to Example 1, wherein the differentdistances (140) locally affect the degree of compression of the expandedparticles (130).

Example 3: Method according to Example 2, wherein the differentdistances (140) are related, preferably essentially proportional, to thethickness distribution in the molded plastic component (135) at leastfor a section of the mold.

Example 4: Method according to any of the preceding Examples, whereinthe expanded particles (130) are partially fused together by heatedsteam and/or electromagnetic radiation.

Example 5: Method according to any of the preceding Examples. whereinduring closing of the mold (200) at least one of the mold parts (212) ispivoted around an eccentrically arranged swivel axis (280); wherein theswivel axis (280) is preferably connected to a mounting plate (270); andwherein preferably deformable spacer elements (290) of different lengthare arranged between the mounting plate (270) and the at least one moldpart (212).

Example 6: Method according to any of the preceding Examples, wherein atleast one of the mold parts (110, 112) comprises several individualsub-parts, and wherein the different distances (140) over which the moldparts (110, 112) are moved together may be individually controlled foreach sub-part.

Example 7: Method according to any of the previous Examples, wherein themold (100) is sealed after the step of loading the mold volume withexpanded particles (130), such that the remaining steps of the methodmay be executed at a different location than the step of loading themold (100).

Example 8: Plastic component (135), in particular a cushioning elementfor a sports shoe comprising: a. expanded particles (130), b. whereinthe local density and/or the local compression stiffness of the plasticcomponent (135) is determined by the degree of local compression of theexpanded particles (130) during molding the component (135).

Example 9: Plastic component (135) according to Example 8, wherein thelocal density and/or the local compression stiffness of the plasticcomponent (135) is essentially constant in at least a portion,preferably all of the plastic component (135).

Example 10: Plastic component (135) according to any of the Examples8-9, wherein the expanded particles (130) comprise at least one of thefollowing materials: expanded thermoplastic polyurethane (eTPU);expanded polyamide (ePA); expanded polyether-block-amide (ePEBA);expanded polylactide (ePLA); expanded polyethylene terephthalate (ePET);expanded polybutylene terephthalate (ePBT); expanded thermoplasticpolyester ether elastomer (eTPEE).

Example 11: Midsole (300) for a shoe, in particular a sports shoe,comprising a plastic component (135) according to any of the Examples8-10 and produced according to any of the Examples 1-7.

Example 12: Midsole (300) for a shoe, in particular a sports shoecomprising expanded particles, wherein the local density of the midsole(300), varies by less than 20%, preferably by less than 15%, morepreferably by less than 10% and most preferably by less than 5% overessentially the whole extent of the midsole (300).

Example 13: Midsole (300) according to any of the Examples 11 or 12,wherein the compression stiffness of the midsole (300) varies by lessthan 20%, preferably by less than 15%, more preferably by less than 10%and most preferably by less than 5% over essentially the whole extent ofthe midsole (300).

Example 14: Shoe, in particular a sports shoe, comprising a midsole(300) according to any of the Examples 11-13.

Different arrangements of the components depicted in the drawings ordescribed above, as well as components and steps not shown or describedare possible. Similarly, some features and sub-combinations are usefuland may be employed without reference to other features andsub-combinations. Embodiments of the invention have been described forillustrative and not restrictive purposes, and alternative embodimentswill become apparent to readers of this patent. Accordingly, the presentinvention is not limited to the embodiments described above or depictedin the drawings, and various embodiments and modifications may be madewithout departing from the scope of the claims below.

1. A method for the manufacture of a plastic component, the methodcomprising: a. opening a mold by a predetermined amount into a loadingposition; wherein the mold comprises at least two mold parts; b. loadinga material comprising expanded particles into the mold; c. closing themold into a closed position; wherein during closing of the mold the atleast two mold parts are moved together over different distances indifferent areas of the mold; d. compressing the expanded particles byclosing the mold; and e. fusing at least the surfaces of the expandedparticles to mold the plastic component; f. wherein the mold has alarger volume in an open position than in a closed position.
 2. Themethod according to claim 1, wherein the different distances locallyaffect the degree of compression of the expanded particles.
 3. Themethod according to claim 2, wherein the different distances are relatedto the thickness distribution in the molded plastic component at leastfor a section of the mold.
 4. The method according to claim 1, whereinthe expanded particles are partially fused together by heated steamand/or electromagnetic radiation.
 5. The method according to claim 1,wherein the deformable spacer elements have different lengths.
 6. Themethod according to claim 1, wherein at least one of the mold partscomprises several individual sub-parts, and wherein the differentdistances over which the mold parts are moved together may beindividually controlled for each sub-part.
 7. The method according toclaim 1, wherein the mold is sealed after the step of loading the moldvolume with expanded particles so that the remaining steps of the methodare executed at a different location than the step of loading the mold.8. The method according to claim 1, wherein the expanded particles arepartially fused together by heated steam.
 9. The method according toclaim 1, wherein the expanded particles are partially fused together byelectromagnetic radiation.
 10. The method according to claim 1, whereinthe expanded particles comprise at least one of the following materials:expanded thermoplastic polyurethane (eTPU); expanded polyamide (ePA);expanded polyether-block-amide (ePEBA); expanded polylactide (ePLA);expanded polyethylene terephthalate (ePET); expanded polybutyleneterephthalate (ePBT); expanded thermoplastic polyester ether elastomer(eTPEE), and combinations thereof.
 11. The method according to claim 1,wherein the plastic component has an essentially constant degree ofcompression.
 12. The method according to claim 1, wherein the plasticcomponent has a non-uniform thickness.
 13. The method according to claim1, wherein the method is conducted in the absence of adhesives or gluingagents.
 14. The method according to claim 1, wherein a first portion ofthe mold forms a first portion of the plastic component with a uniformcompression and a second portion of the mold forms a second portion ofthe plastic component with a non-uniform compression.
 15. The methodaccording to claim 1, wherein the plastic component is a midsole for asports shoe.
 16. The method according to claim 15, wherein local densityin the midsole varies by less than 20% over essentially the wholemidsole.
 17. The method according to claim 15, wherein compressionstiffness in the midsole varies by less than 20% over essentially thewhole midsole.
 18. The method according to claim 1, wherein the materialfurther comprises an energy absorbing material.
 19. The method accordingto claim 1, wherein the material is loaded into the mold from areservoir arranged above the position of the mold and wherein thematerial is loaded by gravity.
 20. A plastic component formed by themethod according to claim 1.